Humidifier separator

ABSTRACT

A separator adapted for use as part of a fluid dispenser system for supplying inhalable fluids and including a liquid source, a gas source, nozzle means, and supporting structure positioned so that gas from the gas source is directed by the nozzle means to aspirate liquid from the liquid source and cooperate therewith to form a desired mixture of liquid and gas. The separator includes an inner member having a radial surface extending therefrom. An outer casing surrounds a portion of the inner member and the radial surface extends into engagement with the outer casing and forms a tortuous passageway between the inner member and the outer casing. The separator is adapted to be positioned within the fluid dispenser system so that the mixture of liquid and gas passes along the tortuous passageway in the separator in contact with the radial surface whereupon the larger drops of liquid are removed from the mixture leaving a remaining mixture of desired consistency which passes from the separator and out of the dispenser for use.

This is a continuation of application Ser. No. 856,397, filed Dec. 1,1977, now abandoned.

BACKGROUND OF THE INVENTION

There are many different types of nebulizers and humidifiers whichemploy a structure that facilitates the mixing of gas and vapor tosupply a patient with an inhalable fluid mixture for breathing andmedicinal purposes. It is common practice to provide a combination ofoxygen and air and to subject this pure gas or a combination thereof tomoisture so that the moisture is entrained in the gas flow path and themixture is introduced to the patient. The vapor which is commonly usedas the moistening agent is effective in easing the breathing of a personparticularly one who is ill and has respiratory problems.

It is often difficult to achieve the desired vapor and avoid thepresence of liquid droplets in the gas and liquid mixture. On the otherhand, insufficient moisture in the gas does not produce the desiredhumidifying effect. Accordingly, it is most desirable to provide thebest possible mixture of gas and vapor for the comfort of the patient.

In certain instances, a bubbling action is employed whereby the gas isbubbled through liquid and in that manner accumulates vapor as part ofthe mixture which is transferred from the humidifier to the patient.This type of system is noisy and can cause patient discomfort orirritation due to the noise. Accordingly, it is desirable to provide ahumidifier which facilitates the formation of a mixture of gas and vaporfor the most beneficial effect on a patient without undesirable noiseassociated with the use of the humidifier. An additional problem ispatient discomfort due to droplets of liquid forming in the system whichwork their way through the system to the mask or nasal cannula directlyconnected to the patient's face. Accordingly, it is desirable to providea humidifier which overcomes this difficulty as well.

The type of environment where the type of humidifier under considerationis most desirable is in the medical profession where a desiredconsistency of mixture of gas and vapor is introduced to a patient toease breathing difficulties and in some cases to introduce medicamentswhich may be included in the vapor to the patient. It is alwaysdesirable with the type of humidifier under consideration to avoid thepresence of droplets of liquid which indicates too much moisture andalso the converse difficulty of lack of sufficient moisture so thatvirtually only gas is introduced to the patient which can causeirritation and potential breathing difficulties particularly over anextended period of time.

Examples of humidifiers with which this invention is applicable aredepicted in U.S. Pat. Nos. 3,572,660; 3,874,379 and 3,836,079.

SUMMARY OF THE INVENTION

Among the primary objectives of the present invention is to provide ahumidifier separator which is designed for use with a nebulizer nozzleto provide a mist of vapor including a mixture of a desired consistencyof gas and liquid for introduction to a patient. In general, the gas ishumidified to prevent the respiratory system from drying withoutproviding a condition where an undesirable amount of liquid isintroduced to the patient.

The structure is designed to utilize a helical surface along which themixture of liquid and gas travels to permit separation of water dropletsfrom the gaseous vapor so that humidified air without air borne waterdroplets is produced for introduction to the patient. The helicalsurface utilizes the velocity of the air spiraling through the threadsof the helix to cause centrifugal force which pushes the water dropletsout of the air and back into the water container.

Another objective of the invention is to provide a humidifier structurewhich is virtually silent thereby eliminating noisy conditions which isparticularly useful in dealing with medical humidifier applications andavoiding patient discomfort or irritation due to excessive noise. Thusthe best possible humidification of air or oxygen or a combinationthereof is produced at a very low or negligible noise level.

A further objective is to provide a separator arrangement employing ahelical surface therein which is adapted to be mounted in an existinghumidifier structure, particularly one which employs a nozzlearrangement to provide a mixture of gas or liquid to form a gas andvapor mixture for introduction to a patient in a conventional fashion.The separator silently removes larger droplets from the mixture formedin the humidifier and returns these larger droplets back to the portionof the container housing the liquid. This type of separator is usefulwith humidifiers employing a nozzle arrangement to aspirate liquid andcombine it with gas introduced under pressure to the humidifier to formthe mixture. The container houses the fluid and has an inlet nozzlearrangement for introduction of the gas under pressure and an outletarrangement for removal of the mixture of moisture and gas forintroduction to the patient.

In summary, a separator is provided which is adapted for use as part ofa fluid dispenser system for supplying inhalable fluids and including aliquid source, a gas source, mixing means, and supporting structurepositioned so that gas from the gas source is directed by the mixingmeans to combine with liquid from the liquid source and cooperatetherewith to form a desired mixture of liquid and gas. A separatorincludes an inner member having a radial surface extending therefrom. Anouter casing surrounds a portion of the inner member and the radialsurface extends into engagement with the outer casing and forms atortuous passageway between the inner member and the outer casing. Theseparator is adapted to be positioned within the fluid dispenser systemso that the mixture of liquid and gas passes along the tortuouspassageway in the separator in contact with the radial surface whereuponthe larger drops of liquid are removed from the mixture leaving aremaining mixture of desired consistency which passes from the separatorand out of the dispenser for use.

With the above objectives among others in mind, reference is made to theattached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In The Drawings:

FIG. 1 is a perspective view of the inner member of the separator of theinvention;

FIG. 2 is an exploded side elevation view of the separator of theinvention and nozzle arrangement employed therewith;

FIG. 3 is a partially sectional side elevation view of the components ofFIG. 2 in assembled condition;

FIG. 4 is a bottom plan view thereof; and

FIG. 5 is a partially sectional side elevation view of the separator ofthe invention mounted in a humidifier with arrows showing the directionof flow of gas, liquid, and a mixture thereof.

DETAILED DESCRIPTION

Separator 20 of the invention is depicted in exploded form in FIG. 2 andincludes an inner member 22 and an outer casing 24. Inner member 22includes a tubular inner portion with a base wall 26 and an upwardlyextending annular side wall 28 terminating in an open top end 30.Extending along a portion of the length of side wall 28 is a radialsurface in the form of a continuous helix 32. Other types of radialsurfaces can also be utilized such as other spiral arrangements andarcuate passageways in place of the helix 32 to accomplish similarresults achieved by the helix 32 as discussed in detail below. Thehelical surface formed by helix 32 is designed with a predeterminedspacing and dimensional thickness so that a desired separation action isachieved. Inner member 22 is designed to work effectively in aconventional type humidifier in separating undesirable water dropletsfrom a vapor/gas mixture to be introduced to a patient. Types ofhumidifiers that can be used include those of a conventional nature suchas described in connection with U.S. Pat. Nos. 3,874,379; 3,572,660 and3,836,079. The operating features of the structure in these patents arereadily adaptable for use in the present system employing separator 20.

Open end 30 of inner member 22 is provided with a plurality of spacedupwardly extending lugs 33 which produce a plurality of openings 34therebetween. Openings 34 provide the passageways between the interiorand exterior of inner member 22. Additionally, base wall 26 is providedwith an aperture 27 for introduction of a tube communicating with liquidin a container to introduce liquid to the interior chamber 38 in hollowinner member 22.

Also on the outer surface of inner member 22 are a plurality of spacedlaterally extending tabs 29. The tabs 29 are positioned between the endsof tubular member 22 and are spaced from helix 32. These tabs 29 areprovided to assist in locking inner member 22 with outer casing 24 inthe manner described below. In the depicted embodiment, there are fourtabs 29 and also four upwardly extending lugs 33 on inner member 22.

The other part of separator 20 is casing 24 and the casing has a topwall 40 and an annular side wall or skirt 42 depending therefrom. Theside wall terminates in an open bottom end 44. A central passageway 46is formed in upper wall 40 for introduction of gas. Extending upwardlyfrom passageway 46 is a tubular connector 48 with annular ribs 50 on itsouter surface to facilitate connection to the gas source. The connector48 has an axial through passageway 52 which communicates with opening 46in bottom wall 40 and with the hollow interior of a tubular housing 54extending inwardly of the bottom wall to the interior of casing 24.Housing 54 has an open end 56 so that a through passageway is providedthrough interconnected connector 48, base wall 40 and tubular housing 54for passage of gas therethrough into the interior of casing 24.

Connector 48 is designed for coupling with the interior of a capstructure of a humidifier as depicted in FIG. 5. Alternatively, thecasing 24 can be formed as an integral part of the underside of a capfor a humidifier system such as that depicted in FIG. 5.

Surrounding open end 44 of casing 24 is a flange 58 formed with anannular recess 60 on its inner surface. Recess 60 is designed forcoupling with tabs 29 of inner member 22 when the two parts areconnected. Inner member 22 is extended through opening 44 in casing 24and is directed toward base wall 40 until lugs 33 engage with the innersurface 62 of base wall 40. The outer diameter of helix 32 ispredetermined so that it fits in snug engagement with the inner surface64 of side wall 42 of the casing. Thus, the only travel path formaterials within chamber 38 of inner member 22 out of the separator isthrough apertures 34 between lugs 33 and then along the helical surfaceof helix 32 and exiting through open end 44 of the casing. Inner member22 is retained in coupled position with outer casing 24 by means of a"snap-in" interengagement between tabs 29 and recess 60 in flange 58.For this purpose, sufficient resilience is provided to the tabs 29 andthe surfaces forming recess 60 to permit the slight deformation and thenreturn to the relaxed position to achieve the "snap-in" effect. With thetabs 29 snapped into position in recess 60 and lugs 33 bottoming againstsurface 62 of base wall 40, the parts of separator 20 are in coupledinterengagement.

The separator is designed to receive a nozzle and siphon tube assembly66 when utilized with a conventional type of humidifier as depicted inFIG. 5. The nozzle and siphon tube arrangement includes a first verticalnozzle 68 which is mounted in frictional interengagement within housing54 so that the passageway through the nozzle communicates with thepassageway through base wall 40 of casing 24. In this manner gas can beintroduced from a gas source directly to nozzle 68. Nozzle 68 has anozzle orifice 70 pointed vertically downward within chamber 38. Coupledwith nozzle 68 through interconnecting structure 72 is a lateral nozzle74. The orifice 76 of lateral nozzle 74 is in alignment with the flowpath exiting from nozzle orifice 70 of nozzle 68. Lateral nozzle 74 isin fluid communication with a siphon tube 78 through hollowinterconnecting structure 80. Siphon tube 78 has an opening 82 at itsfree end for introduction into a reservoir of liquid. The hollowinterconnecting structure 80 also includes a baffle 84 extending intoalignment with the direction of flow from nozzle orifice 70. Lateralnozzle orifice 76 is located between nozzle orifice 70 and baffle 84 sothat after gas passes from nozzle orifice 70 it will pass lateralorifice 76 and siphon liquid through siphon tube 78 and entrain theliquid with the gas to form a liquid/gas mixture. The liquid/gas mixtureis then directed against baffle 84 which acts to break-up liquiddroplets into smaller particles.

As stated above, one end of the siphon tube assembly 66 is mounted inposition by frictionally engaging nozzle 68 with the inner surface ofhousing 54 in casing 24. The siphon tube 78 extends through opening 27in base 26 of inner member 22. In this condition, the separator can becoupled with a conventional humidifier 86 as depicted in FIG. 5. Thehumidifier 86 includes a cap 88 in threaded interengagement with areservoir or container 90. This is achieved by the threaded surface 92of cap 88 interengaging with the threaded surface 94 on the neck ofcontainer 90. The container 90 includes a predetermined volume of liquid96. The liquid can be water alone or mixed with a conventionalmedicament. The cap includes a threaded connector 98 at its upper endfor connection to a conventional source of gas. Extending from connector90 is a central hollow tube 100 which frictionally interengages withconnector 48 of casing 24. In this manner, gas can pass through the capstructure and directly into interior chamber 38 of separator 20. Thefrictional interengagement between connector 48 and tube 100 mountsseparator 20 in position in humidifier 86 with siphon tube 78 extendinginto the liquid 96.

The cap also contains a lateral outlet section in the form of a hollowtubular projection 102. An opening 104 at the inner end of tubularprojection 102 communicates with the interior of humidifier 86 and theopening 106 at the other end of the tubular projection provides the exitfor the desired mixture to be directed to the patient. A conventionalconnector can be mounted on the surface of projection 102 to direct thegas and vapor mixture exiting therefrom to the patient in the desiredmanner.

Humidifier 86, as depicted in FIG. 5, is one of a number of conventionaltypes of humidifiers with which separator 20 is adapted for use.Humidifier 86 in the depicted embodiment is of the type which combinesgas and water to provide a water vapor mixture for introduction to apatient. Connection to the source of oxygen and/or air is made with theuse of connector 98 so that the oxygen and/or air is introduced tonozzle 68 at a predetermined pressure. Naturally the pressure can bevaried to obtain the desired flow. A common pressure employed for thesource of oxygen is 50 psig at the condition of maximum flow.

In use, the oxygen passes from nozzle orifice 70 toward baffle 84. As itpasses lateral nozzle orifice 76, it creates a venturi effect so thatwater 96 is aspirated through siphon tube 78 to exit from nozzle orifice76. The water combines with the oxygen and is entrained to form amixture which is directed against baffle 84. Baffle 84 partially breaksup the water droplets to provide a mixture of water vapor in anintermediate condition.

This intermediate water vapor mixture is then free to exit throughapertures 34 and into contact with helix 32. As the intermediate mixturepasses along the helical surface of helix 32 in a spiral manner, thehelix uses the velocity of the air spinning through the threads to causecentrifugal force to push further water droplets out of the mixture.These drops 108 are then free to fall from the end of helix 32 throughopening 44 back into the volume of liquid 96 within container 90 forreuse. The remaining final mixture of gas and vapor, which is relativelyfree of liquid droplets, then passes to the opening 104 of outletprojection 102 through the open chambers 110 in cap 88 as depicted bythe arrows in FIG. 5. As shown, this final mixture then passes throughprojection 102 out of the humidifier 86 and to the patient. This finalmixture has the desired consistency with respect to relative moisture sothat it is in the most beneficial condition for introduction to thepatient. The system is operated on a very low noise level therebyavoiding patient discomfort or irritation while also providing excellenthumidification of the air.

Thus the several aforenoted objects and advantages are most effectivelyattained. Although several somewhat preferred embodiments have beendisclosed and described in detail herein, it should be understood thatthis invention is in no sense limited thereby and its scope is to bedetermined by that of the appended claims.

I claim:
 1. A hand size separator for a medical fluid dispenser systemfor supplying inhalable fluids, the system including a liquid source, agas source and supporting structure, the separator comprising:means forconnection to a source of gas; means for connection to a source ofliquid; a hollow inner member having a helical radial surface extendingoutwardly therefrom; an outer casing surrounding a portion of the innermember and the helical radial surface extending into engagement with theinner surface of the outer casing so as to form a tortuous passagewaytherebetween communicating with an opening to the exterior of theseparator; a nozzle mounted within the hollow interior of the innermember and positioned to be in communication with the means forconnection to a source of gas and means for connection to a source ofliquid so that when the separator is connected to a source of gas and asource of liquid gas will be directed by the nozzle to aspirate liquidand cooperate therewith to form a desired mixture of liquid and gas;surfaces on the inner member and the outer member forming a passagewaybetween the hollow interior of the inner member and the exterior thereofso that the mixture of gas and liquid produced within the inner memberis directed into engagement with the helical radial surface between theinner and outer members and the mixture passes along the tortuouspassageway in the separator in contact with the radial surface whereuponthe larger droplets of liquid are removed from the mixture for drainagethrough the opening to the exterior of the separator leaving a remainingmixture of desired consistency to be supplied to a patient; theseparator being mounted in a liquid container to form a nebulizer orhumidifier for introducing therapeutic fluids to a patient; the liquidcontainer having an inlet section and an outlet section; the inletsection having means thereon for removable connection to a source of gasand the liquid container having a reservoir of liquid therein forming asource of liquid; the nozzle of the separator positioned in the liquidcontainer in communication with the liquid therein and positioned withrespect to the inlet section so that gas entering the container isdirected to the nozzle through the means on the separator for connectionto a source of gas thereby permitting the nozzle to aspirate liquid fromthe container and cooperate in formation of a mixture of liquid and gas;the separator being positioned in the liquid container in a position sothat the mixture of desired consistency communicates with the outletsection of the container for passage therethrough for transmittal to thepatient; the liquid container including a hollow base for housing theliquid with an open top end and a removable cap coupled with the opentop end of the base, the separator being removably mounted in the cap,the inlet section being located in the cap; and the separator beingpositioned in the container so that the separated drops of liquidexiting from the tortuous path will fall by gravity through the openingto the exterior of the separator and drain into the reservoir of theliquid container for reuse.
 2. The invention in accordance with claim 1wherein the outer casing is tubular to form an annular side wall and hasa base wall at one end of the side wall and is open at the end oppositeto the base wall, the helical radial surface terminating at the open endof the outer casing which forms the opening to the exterior of theseparator which is in communication with the end of the tortuouspassageway between the inner member and the outer casing.
 3. Theinvention in accordance with claim 2 wherein the inner member positionedin the outer casing is provided with an open upper end adjacent the basewall of the casing and a lower end wall, an aperture in the base wall ofthe casing for introduction of gas from a gas source when connected withthe separator for mixing with liquid aspirated by the nozzle when theseparator is interconnected with a source of liquid, the liquid beingwater and the gas being at least one of oxygen and air, and theseparator being formed of disposable plastic material.
 4. The inventionin accordance with claim 3 wherein a plurality of spaced lugs extendupwardly from the upper end of the inner member into engagement with thecasing, the spaces between the lugs forming apertures to provide apassageway from the interior of the inner member to the exterior thereofinto communication with the helical radial surface, a plurality ofspaced radial tabs extending from the outer surface of the inner memberintermediate the ends thereof, an annular recess on the inner surface ofthe casing in position for alignment with the radial tabs on the outersurface of the inner member, and the tabs and casing having sufficientresilience therebetween so that the tabs can snap into position in theannular recess thereby coupling the inner member and outer casingtogether.
 5. The invention in accordance with claim 4 wherein the nozzleincludes a first nozzle means thereon for connection to a source of gas,the first nozzle means being mounted in the hollow interior of the innermember and positioned to direct gas introduced under pressuretherethrough in a downward direction, the nozzle including a secondnozzle means positioned perpendicular to the first nozzle means in thehollow interior of the inner member and adjacent to the first nozzlemeans for the eduction of a spray of liquid therefrom, a siphon tube influid communication with the second nozzle means and extendingdownwardly and outwardly of the inner member with means thereon to bringthe siphon tube into fluid communication with a liquid source, and abaffle member adjacently below said first and second nozzle means ontowhich the spray of the mixture of liquid in gases to be directed tonebulize the same prior to exit of the mixture from the hollow interiorof the inner member into communication with the radial surface.
 6. Theinvention in accordance with claim 1 wherein the helical surface iscontinuous about the outer surface of the inner member.